Home

KTM 990 SUPER DUKE, 990 SUPER DUKE R Motorcycle User Manual

1. E yH g D Se i General information on KTM disk brakes BRAKE CALIPERS The front brake calipers 1 have 4 brake pistons and are radially bolted to the fork legs The front brake disks are designed as floating brake disks i e they are not firmly con nected to the front wheel The lateral balance ensures that the brake pads always have the best possible contact to the brake disk Apply Loctite 243 to the screws 2 on the brake caliper support and tighten to 45 Nm The rear brake caliper 3 has 1 brake piston and is designed as a floating brake caliper i e it is not firmly connected to the brake caliper support The lateral balance ensures that the brake pads always have the best possible contact to the brake disk UN WARNING OSS For safety reasons always have maintenance work and repairs to the brake system performed by an authorized KTM workshop BRAKE PADS Your motorcycle is equipped with sintered brake pads in the front and rear and homologated accordingly They guarantee maximum braking performance Front brake pads HAWK 7342 49 Rear brake pads TOSHIBA TTH 38 GF UN WARNING CSS Brake pads available in the accessory trade are often not authorized for operation of your KTM motorcycle in road traffic The brake pads design and friction factor and therefore the braking power can deviate significantly from original KTM brake pads If you use differ
2. aqn pe y Sulaeys uo yue jan uo S Y eqn awedy uo S A eqn awed uo S H yue N Uo S T yue jan uo 2 3 4 5 6 7 yeas Japun S y eqn awedy uo Sticker positions yeas Japun CONSUMER INFORMATION FOR USA ONLY 89 1 EAVP 2 Type label CAN 3 iienaa a AUTOMOBELES DU CANADA EN VIGUEUR A LA DATE DE SA FABRICATION 5 Technical information 611 03 498 000 RON95 unleaded USA PREMIUM RON 91 120 70 17 speed index ZR rider only 2 4 bar 34 psi max payload 2 4 bar 34 psi PROHIBITED BY U S FEDERAL LAW SEE OWNER S MANUAL Motorcycle Type 990 SUPEROUKE Date manufactured 2006 07 04 VIN VEOOQ40TMIO0000 180 55 17 speed index ZR rider only 2 4 bar 34 psi max payload 2 6 bar 37 psi 185 kg 408 bs max total weight 387kg 854lbs full ic LOW 50 5W 40 under 0 C 32 F Further information see owners handbook 9 Type label USA MFD BY KTM SPORTMOTORCYCLE AG AUSTRIA MOTORCYCLE DATE 387 kg 180 kg WITH 120 70 17 TIRE 58W TYPE 3 50 17 RIM AT 35psi 2 4 bar COLD 551 Ibs 250 kg WITH 180 55 17 TIRE 73W TYPE THIS VEHICLE CONFORMS TO US EPA AND CALIFORNIA REGULATIONS APPLICABLE fi _5 50 17 RIM AT 36 psi 2 4 bar COLD TO 2007 MODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED TO THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL MOTOR LAPEN
3. 62 Function buttons on combined instrument 8 Checking the engine oil level 1 0 0 0 cee ee eee 66 Fuses for individual power consumers 00000005 56 Checking the front brake fluid level 050 44 General information on KTM disk brakes 5 42 Checking the front brake padS 0 0 0 0 00 eee eeee 45 General tips and warnings for starting the motorcycle 22 Checking the oil level of the hydraulic clutch 64 Handibrake lever sas 6 4 549462 ee Sad baed bad be wd ea et 7 Checking the rear brake fluid level 000005 46 Helmet lok in 6 csc kad cae a ae oa a saw eee a a 17 Checking the rear brake pads 0 0 0 cee eee eee 46 iHOlding Strap een r 0 dure le a eed Ae ed Gla Ye aad ee 17 HEAD WORD INDEX 86 How to change the handlebar position Super Duke R 65 Starting up after immobilization 22 05 78 lenition LOCK gt Spaces dete wack beard eos Akai in Se AAP cites ela 14 Stopping and parking cege e E ei EE ee 29 Important information n aaea aaae 2 Strage wavs aa etea aar ASE dd RRN dad DOR DEANE E UE NEE LE 78 WAGEXS 5 4 ba aio ad th od a a ad N a a gal a ON ed Hed ae A Tachometer s 5 ce og ahs Sueded Saeed bald ty alate 12 Indicator lampS 22056 c065 08 teow Gg She awe a hae wes 13 Technical specifications chassis 0 00 00 eae 79 Instructions for initial operation 0 0
4. The green indicator lamp will light up when the gearbox is in an idling position Qa Cee The blue indicator lamp will light up when the high beams are switched on The red warning light will light up when the cooling liquid has reached a tempera ture of approx 120 C 248 F The orange warning lamp will light up when the fuel level has reached the reserve mark At the same time the display will automatically change to TRIP F see TRIP F The red warning lamp lights up when the ignition is switched on but the engine is not running When the engine is started the warning lamp will go out as soon as the oil pressure is high enough The orange warning lamp fuel injection briefly lights up when the ignition is switched on It will go out when the gasoline pressure is high enough If this warning lamp lights up while driving a component in the injection system is defective The error can be identified by means of a blink code see Trouble shoot ing 3 0e amp O The red warning lamp will light up if the voltage in the on board electrics drops below 10 volts Immediately drive to the nearest authorized KTM workshop and have the electrical system checked OPERATION INSTRUMENTS 14 SZ Ignition lock The ignition lock has 3 switching positions 0 Ignition off engine can t be started O Ignition on engine can be started A Ignition off handlebar blocked To switch the ignition to position A t
5. ZN WARNING OSC If chain tension is too great parts within the secondary power transmission chain chain sprockets transmission and rear wheel bearings will be subjected to unnecessary stress resulting in premature wear and even chain breakage Too much slack in the chain on the other hand can result in the chain jumping off the chain wheels If this happens the chain could also block the rear wheel or damage the engine In either case the operator is likely to lose control of the motorcycle Correcting the chain tension Loosen the collar nut 2 loosen the counternuts 3 and turn the left and right adjustment screws 4 the same distance Tighten the counternuts 3 To make sure the rear wheel is aligned the marks on the chain tensioners must be in the same position on the left and right in relation to the reference marks A Before tightening the wheel spindle make sure the chain tensioner 5 rests against the adjustment screws and the rear wheel is aligned with the front wheel Tighten the collar nut 2 to 90 Nm ZN WARNING SSCS If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle MAINTENANCE WORK ON CHASSIS AND ENGINE 41 Chain maintenance Maintenance of the X ring chain is reduced to a minimum Rinse off any heavy dirt with plenty
6. Engine oil too thin viscosity Check engine oil level when the engine is warm correct if necessary Use thicker engine oil see chapter Engine oil Headlight and position light fail Blown fuse Replace fuse 2 Flasher lights brake light horn and combined instrument fail Sicherung durchgeschmolzen Replace fuse 3 Time is not displayed or not cor rectly displayed Blown fuse thus no continuous power supply Replace fuse 6 and set the clock TROUBLESHOOTING TROUBLE 15 CAUSE REMEDY The battery is discharged The ignition power consumer has n t been switched off The battery isn t charged by the generator Recharge the battery according to the relevant instructions Voltage regulator and generator should be checked by an authorized KTM workshop No values are visible in the com Blown fuse bined instrument display Replace fuse 3 The speed indication on the Pickup cable is damaged or con combined instrument is not tacts on the cable connector have working oxidized Check the pickup cable for damage visit an authorized KTM workshop The blink code indicates which component is affected by an error This allows the error to be identified if no diagnosis tool is available BLINK CODE SIGNAL COMPONENT ERROR DESCRIPTION ENGINE 02 Pulse generator Malfunction Stalls 06 Throttle sensor Output signal too low high Contin
7. 4 if 06 u teehee sede hot ol oboe ewes 26 CONSUMER INFORMATION FOR USA ONLY 87 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause an accident resulting in injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying KTM North America Inc If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remady cam paign However NHTSA cannot become involved in individual problems between you your dealer or KTM North America Inc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or visit the website www nhtsa dot gov or write to NHTSA U S Department of Transportation 400 7th Street Southwest Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline NOISE EMISSION WARRANTY KTM Sportmotorcycle AG warrants that this exhaust system at the time of sale meets all applicable U S EPA Federal noise standards This warranty extends to the first per son who buys this exhaust system for purposes other than resale and to all subsequent buyers Warranty claims should be directed to KTM North America Inc 1119 Milan Avenue Amherst Ohio 44001 Telephone 440 9853553 TAMPERING WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED FEDERAL LA
8. The adjusting screws 3 are located on the upper end of the fork legs More information is provided in the chapter Adjusting the fork and shock absorber OPERATION INSTRUMENTS 20 Spring preload of the fork The fork s preload can be adjusted by means of the adjusting screws 1 More information is provided in the chapter Adjusting the fork and shock absorber Damping action during compression of shock absorber The shock absorber s damping action during compression travel compression damping can be adjusted This allows you adjust the shock absorber s damping behavior to match your driving style and the payload The damping rate can be adjusted in the low and high speed range Dual Compression Control The designation low and high speed refers to the movement of the shock absorber and not to the motorcycle s driving speed The adjusting screw 2 for the low speed range can be adjusted with a screwdriver The adjusting screw 3 for the high speed range can be adjusted with a 17 mm socket wrench More information is provided in the chapter Adjusting the fork and shock absorber OPERATION INSTRUMENTS 21 Rebound damping of shock absorber The shock absorber s damping action during rebound travel rebound damping can also be adjusted This allows you adjust the damping behavior to match your driving style and the payload The adjusting screw 1 is located on the bottom of the shock absorber More informa
9. HE MOs FIHAUST EMISSION STANDARD IN CALIFORNIA susie SAFETY STANOARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE t VEKVA4JAXSAN23456 USE THIS SPACE FOR NOTES 11 2006 FOTO MITTERBAUER
10. OCS If possible check the cooling liquid level when the engine is cold If you need to remove the radiator cap when the engine is hot hold the cap with a cloth and open slowly allow ing any excess pressure to escape danger of scalding i CAUTION Accumulated soil and lime on the radiator cap will cause you to lose cooling liquid Carefully clean the radiator cap gasket 2 and sealing area each time If more than 1 liter of cooling liquid needs to be added you will need to bleed the cool ing system Bleeding the cooling system Take off the left and right spoilers To take off the spoilers remove the screws 3 and 4 on each side MAINTENANCE WORK ON CHASSIS AND ENGINE 63 Remove the bleeder screw 5 on the left side of the radiator To completely bleed the cooling system the motorcycle must be raised approx 50 cm 20 in in the front Add cooling liquid until it runs out of the vent holes without bubbles and immediately mount the screw to prevent air from entering the radiator Completely fill the radiator with cooling liquid Mount the radiator cap and move the motor cycle into a horizontal position again Now fill the compensating tank 6 with cooling liq uid until it reaches a level between the MIN and MAX marks Close the compensating tank and mount both spoilers MAINTENANCE WORK ON CHASSIS AND ENGINE 64 Changing the basic position of the clutch lever The basic position of th
11. SPEED Turn adjusting screw wrench size 17 mm clockwise as far as it will go Super Duke Turn 1 5 turns in a counterclockwise direction Super Duke R Turn 2 5 turns in a counterclockwise direction UN WARNING OOS The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do anymaintenance work yourself Severe injuries could be the result Never unscrew the black screw connection 24mm Rebound damping of shock absorber By using the adjusting screw 2 the degree of damping of the rebound can be adjusted Turn the knob in a clockwise direction to increase damping turn it in a counterclockwise direction to reduce damping during rebounding STANDARD ADJUSTMENT Turn adjusting screw 2 clockwise as far as it will go Turn 12 clicks in a counterclockwise direction ZN WARNING OOS The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the result MAINTENANCE WORK ON CHASSIS AND ENGINE 40 Checking the chain tension Place the motorcycle on the side stand Switch the transmission to neutral and push the chain up The distance between the chain and the swing arm should be 7 mm when the upper part of the chain 1 is tensioned see drawing Correct the chain tension if necessary
12. THE STARTER TIP SWITCH whether you accelerated while starting the transmission is switched to idle Check if the emergency OFF switch is on Check if the ignition is on the headlight is on If this is not the case the battery is dis charged If the lights are on proceed as described in the Trouble shooting section or contact a KTM dealer IF THE ENGINE CRANKS BUT DOES NOT START WHEN YOU ACTUATE THE STARTER TIP SWITCH whether you accelerated while starting whether the FI indicator lamp is blinking if yes check Troubleshooting Blink codes table Check if sufficient fuel is in the tank If this is not the case refill the tank if sufficient fuel is in the tank pro ceed as described in the Trouble shooting section or contact a KTM dealer NOTE This motorcycle is equipped with a safety start ing system The engine can only be started if the transmission is in neutral or the clutch lever is pulled If the side stand is folded down the engine can only be started if the trans mission is in neutral or the clutch lever is pulled The engine will stall if a gear is engaged and the clutch lever is released with the side stand folded down Starting off Pull the clutch lever and engage lst gear Slowly release the clutch lever while you gen tly accelerate ART as Do not attach a helmet or other objects to the helmet lock rope while driving You can easily lose
13. To refill engine oil take off the right spoiler 1 by removing the screws 2 Also remove the screws 3 and take off the spoiler Unscrew the plug 4 and refill engine oil Wait 20 seconds and check the oil level again The quantity of oil between the MIN and MAX marks is 0 3 liter Mount the plug and check the engine for leaks Finally mount the spoilers i CAUTION Insufficient amounts of or low grade engine oil lead to premature wear in the engine Do not overfill the engine case Do not underfill the engine case MAINTENANCE WORK ON CHASSIS AND ENGINE 68 ZAN F Changing the engine oil and the oil filter cleaning the oil screen i CAUTION You may only change the engine oil yourself after the warranty period has expired The war ranty will become void if you change the oil yourself during the warranty period NOTE The LC8 engine has a dry sump lubrication system The engine oil is pumped from the oil sump in the engine case to the oil tank The engine oil must also be drained from the oil tank during an oil change Since many parts must be demounted for an oil change we recommend having the engine oil changed by an authorized KTM workshop During the guaranty period the oil change must be performed by an authorized KTM mechanic Otherwise the guarantee will become void The engine oil change is to be carried out when the engine is still warm MN WARNING An engine having been run warm a
14. Zahl MON Motor Octane Number 5W 40 10W 50 Engine oil Only use fully synthetic engine oils that meet the JASO MA quality requirements see information on the can KTM recommends Motorex Power Synt 4T in the 1OW 50 viscosity for temperatures over 0 C 32 F or 5W 40 for temperatures under 0 C 32 F HEAD WORD INDEX 85 Accessories and payload 0 cece eee 23 CClEANMINS 2 28 ots ofa ok ote sla s AAE lee ata ie Atte aa 77 Adjusting compression damping of fork 4 87 VClutch lever wie nae a baw eet A Pie Sete dd anes boat 7 Adjusting rebound damping of fork 000005 37 Combination switch 0 0 0 0 ccc ee 14 Adjusting the basic position of the hand brake lever 44 Combined instrument 2445 24248 sad sev wl cond he wall wa ee 8 Adjusting the fork and shock absorber 05 37 Combined instrument display 0 000 c eee eee 8 Adjusting the handlebar tilt 0 00 000 eee 64 Compression damping of fork 0 0 00 eee eee 19 Adjusting the headlight range 0 0 0 0 cee eae 58 Compression damping of shock absorber 38 Adjusting the spring preload on the fork 0 38 Conservation for winter operation 00 00 e eae 77 Adjusting the steering damper Super Duke R 65 Consumer information for USA only 0225055 87 Baggage lOOpS ra rina tea Se od ee todd be Boe eee 16 Cooling liquid t
15. control of the motorcycle Shifting Riding You are now in first gear refered to as the drive or uphill gear Depending on the con ditions traffic road gradient etc you can shift to a higher gear Close throttle at the same time pull clutch lever and shift to the next higher gear Let clutch lever go again and carefully open throttle Do not shift gears and accelerate carefully in curves Only accelerate to the extent that road and weather conditions allow Be especially care ful when you accelerate in curves Abrupt opening of the throttle can cause the motor cycle to go out of control and also increases fuel consumption By shifting down use the brakes if neces sary and close throttle at the same time Pull clutch lever and shift down to the next gear Let clutch lever go slowely and open throt tle or shift down again If the engine is killed f ex at a crossing sim ply pull the clutch lever and start It is not necessary to switch the gear to NEUTRAL Stop immediately if the FI indicator lamp lights up while driving The FI indicator lamp will start blinking as soon as the transmission is in neutral The rhythm of the blinking lamp will let you determine the two digit blink code e g Blink code 34 FI blinks 3x long 4x short pause Blink code 06 FI blinks 6x short pause The blink code will indicate which compo nent is defective see Troubleshooting This makes it possible to pinpoint the defect if a
16. diagnostic tool is unavailable ART as Avoid abrupt load changes while riding around bends and on wet or slippery ground Otherwise you might easily lose control over your motorcycle DRIVING INSTRUCTIONS 28 AE While riding your motorcycle never switch the ignition lock to positions and amp Do not try to change the settingsof the combined instrument while driving Your attention will be distracted from the traf fic and this may cause you to lose con trol of your motorcycle The frost symbol in the combined instru ment will start to blink on icy roads Adapt your speed to the road and weather con ditions The passenger must hold on to the driver or the holding strap on the seat while rid ing and keep his her feet on the passen ger footrests Regularly make sure that the baggage and cases are tightly fastened After falling with the motorcycle check all functions thoroughly before starting up operations again A bent handlebar must always be replaced Never try to straighten the handlebar because this will cause it to lose its sta bility CAUTION High rpm rates when the engine is cold have an adverse effect on the life of your engine We recommend you run the engine in a moderate rpm range for a few miles giving it a chance to warm up After that no further precautions in this respect need be taken The engine has reached operating temperature as soon as the 4t
17. every 15000 km or every 2 years Check rim joint Check tire condition and inflation pressure Check chain sprockets and chain guides for wear force fit and tension Check bolts on pinion and chain sprocket for locking devices and a tight fit Lubricate chain Check wheel bearings and jerk damper for play IF MOTORCYCLE IS USED FOR COMPETITION 7500 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE Service intervalls should never be exceeded by more than 500 km Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver 990 SUPER DUKE R 2007 ADDITIONAL SERVICE WORK TO BE PERFORMED UNDER A SEPARATE ORDER at least once a year every 15000 km or every 2 years Perform complete fork maintenance Perform complete shock absorber maintenance Clean and lubricate steering head bearing and sealing elements Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change coolant fluid PERIODIC MAINTENANCE SCHEDULE 990 SUPER DUKE R 2007 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate actuating
18. of water Residual used grease must be removed prior to lubrication Motorex Chain Clean 611 After drying use a chain spray specially designed for X ring chains Motorex Chainlube 622 MN WARNING No lubrication is allowed to reach the rear tire or the brake disk eitherwise the road adherence and the rear wheel braking effects would be strongly reduced and the motor cycle could easily get out of control The chain does not have a chain joint for safety reasons Always have the chain replaced in an authorized KTM workshop where the service technicans have the required riveting tool Never mount a normal chain joint Also check sprockets and chain guides for wear and replace if necessary Checking the chain for wear To check the chain for wear proceed as follows Switch the transmission to idle and put a load of approx 15 kilograms 33 Ibs on the lower part of the chain see illustration Now measure the distance between 18 chain rollers on the upper part of the chain The chain needs to be replaced when the max 272 mm distance is 272 mm 10 70 in Since chains do not always wear evenly repeat the meas urement at different parts of the chain CDC f CCD Replace the chain if any X rings are missing lt A AS 123 16 17 18 NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets MAINTENANCE WORK ON CHASSIS AND ENGINE 42
19. seat lock 1 can be locked with the ignition key To remove the seat insert the ignition key and turn 90 in a clockwise direction Lift the seat in the back while pressing near the holding strap and pull off towards the back To mount the seat place it on the motorcycle and position the hooks 2 on the bottom of the seat behind the dollies 3 on the subframe Press down on the seat near the holding strap while sliding it forwards The two tabs 4 must hook onto the tank Turn the ignition key in the seat lock 90 in a counterclockwise direction and pull off Check whether the seat is mounted correctly Baggage loops 4 loops 5 are mounted on the bottom of the seat to which small pieces of baggage can be fastened Fold the loops towards the outside to make them accessible when the seat is mounted UN WARNING CSC Baggage weight max 5 kg OPERATION INSTRUMENTS 17 Tool set The tool set 1 is located in the storage compartment under the seat Helmet lock The steel rope 2 in the tool bag can be used to secure a helmet To secure remove the seat run the rope through the helmet attach both ends to the hook 3 and mount the seat ZN WARNING CSCS The helmet lock is provided to secure the helmet to the motorcycle when parked Do not attach the helmet or other objects to the steel rope while driving You can easily lose con trol of the motorcycle Holding strap The passenger should
20. should be checked regularly on a cold tire Adapt the air pressure to the pS motorcycle s total weight Proper pressure ensures optimum driving comfort and extends 2 4 bar 34 psi TIRES AIR PRESSURE 990 Super Duke R Road driver only maximum payload the life of your tires Do not mount tires which have not been approved by KTM Other tires could have adverse effects on the way your motorcy cle rides Use tires of the same brand and type for the front and rear wheels Worn tires can have a negative effect on how your motorcycle performs especially on wet surfaces If air pressure is too low abnormal wear and overheating of the tire can result New tires have a smooth surface which means that they must be run in to achieve full grip For this purpose ride the motor new tires tilting the vehicle at different angles so that all sections are properly roughened Tires will not display their full grip characteristics until they are properly run in For reasons of safety it is recommended to exchange the valve insert whenever a new tire is mounted For your own safety replace damaged tires f l cycle carefully at moderate speed during immediately the first 200 kilometers 125 miles with Battery The battery is located in the front spoiler in front of the engine and is maintenance free It is not necessary to check the electrolyte level or to refill water Simply k
21. the sprockets and a worn out chain can tear In both cases this can damage other motorcycle components and cause the motorcycle to go out of con trol A chain that is too tight or not greased will cause unnecessary wear to the chain and sprockets 3 TIRES Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 4 BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by a KTM specialist as com plete failure of the braking system can be avoided Also check the state of the brake hose and the thickness of the brake linings Check free travel at hand brake lever and foot brake lever 5 CABLES Check the throttle cable for correct adjustment and smooth operation DRIVING INSTRUCTIONS 25 6 COOLING FLUID Check the level of cooling fluid when the engine is cold 7 ELECTRICAL SYSTEM Start the engine and check the headlight tail lamp brake light turn signals indicator lamps horn and emergenc
22. wax based anti corrosion agent ART nis ie arene Seen anes a ee ae Keep anti corrosion agent from getting into contact with the brake discs for otherwise this will significantly reduce the braking power 1 CAUTION After rides on salted roads clean motorcycle thoroughly with cold water and let it dry well STORAGE 78 If you plan to immobilize your motorcycle for a longer period of time proceed as follows Run the tank empty to be able to add fresh fuel when starting up again Clean the motorcycle thoroughly see CLEANING chapter Change the engine oil and the oil filter old engine oil contains aggressive impurities Check the quantity of antifreeze and cooling liquid Remove and charge the battery see Charging the battery chapter If possible jack up the motorcycle to lift the wheels off the ground The storage site should be dry and not subject to larger temperature fluctuations Cover the motorcycle with a permeable cover or blanket Do not use impermeable material since it will not allow and moisture to escape and will cause corrosion 1 CAUTION Do not briefly run the engine of an immobilized motorcycle since the engine will not become warm enough and any vapor produced during the combustion process will condense and cause the valves and exhaust to rust STARTING UP AFTER IMMOBILIZATION Mount the charged battery pay attention to the polarity and set the clock Fill fresh
23. 00 22 Technical specifications engine 00 eee 83 Introduction oz ft isons eS ood ene rn bet Ae ey caret ate 1 Tires air pressure ok ee 51 JUMP SIAM 4d wh doh ne Paeohedodeadedd done oad hod BAS 7 TOOSE kde d od ead os Og behead Ooh Gore does hee 17 Main fuses 245 0 2 0 trad ethers a 55 Troubleshooting 0 0 ccc ee eae 72 Maintenance work on chassis and engine 36 Operation instruments 0 0 00 c cee eee eee 7 Periodic maintenance schedule 20 000005 32 Rebound damping of fork 0 0 cee eee 19 Rebound damping of shock absorber 0005 39 Rebound damping of shock absorber 00055 21 Refilling engine oil 2 2 eee 67 Removing and remounting the battery 53 Replacing the brake light and taillight bulbs 59 Replacing the flasher bulbs 1 0 0 0 0 eee eee 59 Replacing the headlight lamp cee eee 57 Running inthe LC8 engine 0 0 ee eee 22 Seat lock removing the seat 2 ke ee 16 Serial number locations 000000 e eee ee eee 6 SHIPIEVED se aenn ded rhagoadwd beta he done ot4 aos 18 ShHitting RIGiNg Teeraa sie Raed oe HA Ra Ae a Sass S 27 Side Stand mines Atte ce i gve Hata oe a ea a eee ee eas 18 Spring preload of the fork 2 0 cee ee 20 Starter tip switch Emergency OFF tip switch 15 Stating Olt Ab arene annene Ake Miche at ne Mt hoe odes Hi Rae teh 27 Starting the engine
24. 1 The frost symbol will start to blink regardless of the mode if the ambient temperature drops below 3 C 37 5 F ODO 2 Displays the total kilometers or miles traveled This figure will not be cleared if the battery is disconnected GE 88 FAG OPERATION INSTRUMENTS 11 OO H8 5838 LOI BE e SI OI Bg F 714 TRIP 1 1 The trip meter 1 is always active and counts up to 999 9 It is used to measure the length of the trip or the distance between 2 refueling stops TO RESET TRIP 1 To reset the trip meter 1 to zero switch on the ignition select the TRIP 1 display mode and press the SET button more than 2 seconds Press the MODE button to go to the next display mode TRIP 2 2 The trip meter 2 is always active and counts up to 999 9 It is used just like TRIP 1 TO RESET TRIP 2 To reset the trip meter 2 to zero switch on the ignition select the TRIP 2 display mode and press the SET button more than 2 seconds Press the MODE button to go to the next display mode TRIP F 3 When the fuel level reaches the reserve mark the display will automatically switch to TRIP F and begin to count no matter which display mode was active before At the same time the fuel warning lamp will light up You will still have enough reserve fuel for at least 30 kilometers After refueling it will take approx 3 minutes for the fuel lamp to go out TRIP F t
25. 2007 990 SUPER DUKE 990 SUPER DUKE R ART NR 3 211 151 EN INTRODUCTION We would like to congratulate you on your purchase of a KTM motorcycle You are now the owner of a state of the art sport motorcycle that guarantees to bring you lots of fun and enjoyment provided that you clean and maintain it appropriately Please insert the serial numbers of your motorcycle in the boxes below Frame number Stamp of dealer Engine number Key number All information contained is without obligation KTM Sportmotorcycle AG particularly reserves the right to modify any equipment technical specifications prices colors shapes materials services service work constructions equipment and the like so as to adapt them to local conditions or to cancel any of the above items all without previous announcement and without giving reasons KTM may stop manufacturing certain models without previous notice KTM shall not be held liable for any deviations of availability and or ability to deliver illustrations descriptions printing and or other errors The illustrated models partly contain extra equip ment which is not applied to standard models 2006 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit a T
26. ANDARD ADJUSTMENT Turn adjusting screw counterclockwise as far as it will go Super Duke R Turn 5 turns in a clockwise direction no i 2 is E3 a BASIC SETTING SHOCK ABSORBER WP 4618 BAVP pe a S E fo O a0 Ss fo a Basic Setting Driving Sport Maximum Payload Driving Sport Race course Maximum Payload Hi 2 oe Compression adj Low Speed clicks N m HG 3 a m o an ol ez Compression adj High Speed turns Rebound adjuster clicks N n Pi a RID D Basic Setting Ain o aN Spring preload mm Compression damping of shock absorber The shock absorber can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber compression rates The high speed setting is effective at fast compression rates Turning in a clockwise direction will increase the damping turning counterclockwise will decrease the damping MAINTENANCE WORK ON CHASSIS AND ENGINE 39 STANDARD ADJUSTMENT LOW SPEED Turn adjusting screw 1 clockwise as far as it will go Turn 20 clicks in a counterclockwise direction STANDARD ADJUSTMENT HIGH
27. ATION INSTRUMENTS 0002000 eee eee 7 Clutch lever Cil ai eas otk aces ac nana clea diate a 7 Hand brake lever 2 00 00 00 eee ee 7 Combined instrument 000 0c eee e eee 8 Function buttons on combined instrument 8 Combined instrument display 0 0 0 0 eee eae 8 Cooling liquid temperature display 005 12 Tachometer os siecstnieal teen tee nd wR ets REO A een 12 Indicator lamps ii ica thes dala the 2 eke ele ae deca 13 LSMITIONIOCK e preen erect aan a e a nee rt eee 14 Combination switch 02 0000 cee ee ee eee 14 Starter tip switch Emergency OFF tip switch 15 PUG Cap nh ac 2c toca out Soe ad 20 Ac ales ee tae deeds 15 Seat lock removing the seat 1 ee ee 16 Baggage lOOps d od an a amas Rilo amacd deel a oar i ede 16 TOOlSCl ee hrada ranpe Eea d Rao a es Bee ae 17 Helmet loek existe sew Aare ils a a E a ete tive el a 17 HoldingsstraD ge ronr Sei ae Sets a a OREO A 17 Shift lEVe n and ai a a open APE ahd AD 18 Sid st nd eos csi cowie eRe awe BA Ra wld wae tS 18 Foot brake pedal i ss co toa widow eda nia eaa Sede koe 18 FOOUESIS suai aa a aware Oh ech Guan Seca a 19 Compression damping of fork 000 ee eee 19 Rebound damping of fork 2 000 cee eee 19 Spring preload of the fork na nn nananana aaan 20 Damping action during compression of shock absorber 20 Rebound damping of shock absorber 00 21 GENERAL TIPS A
28. Cooling system na nn ce she dad ere neha gesde tnd 60 Checking the cooling liquid level in the compensating tank 61 Checking the cooling liquid level in the radiator 62 Bleeding the cooling system 1 nananana aana 62 Changing the basic position of the clutch lever 64 Checking the oil level of the hydraulic clutch 64 Adjusting the handlebar tilt 0 000008 64 How to change the handlebar position Super Duke R 65 Adjusting the steering damper Super Duke R 65 EMSINGLOM acs xcnoots Mise mites Om ae ats ine heel es Gee 66 Checking the engine oil level 00 00 0000 ee 66 Refilling engine oil 2 cee 67 Changing the engine oil and the oil filter cleaning the oil sereen 2 s 40040 oot whee we wed 68 SERIAL NUMBER LOCATIONS 6 Chassis number Type label The chassis number is stamped on the right side of the steering head tube Enter this num ber in the field on page no 1 The type label is located on the right frame tube under the seat Engine number engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket Enter this number on page 1 OPERATION INSTRUMENTS 7 Clutch lever The clutch lever 1 is fitted on the left hand side of the handle bar The adjusting screw A is used to change the original position of the clutch lever see maintenance work on chas sis and engine The clu
29. EMEDY Engine does not start when the starter button is actuated Operating error Discharged battery Blown fuse Main fuse is blown Defect ignition lock or emergency OFF switch Defect safe starting system Turn on the ignition switch the gear to neutral and switch the emergency OFF switch on do not accelerate while starting the engine Recharge the battery and investigate the causes for discharg ing contact an authorized KTM workshop Replace fuse 1 Remove the front spoiler and replace the main fuse Check ignition lock and emergency OFF switch contact an authorized KTM workshop Contact an authorized KTM workshop The engine cranks only with pulled clutch lever A gear is engaged A gear is engaged and the side stand is still folded down Defect safe starting system Shift the transmission to neutral Shift the transmission to neutral Contact an authorized KTM workshop Engine cranks with gear engaged Defect safe starting system Contact an authorized KTM workshop TROUBLESHOOTING 13 TROUBLE CAUSE REMEDY Engine cranks but doesn t start Operating error Blown fuse for the fuel pump Clutch not attached to the fuel line The plug and socket connector on the wiring harness is oxidized Error in the injection system A gear is engaged and the side stand is folded down Pay attention to starting off information see driving instructions Repla
30. N and a MAX mark The brake fluid level may not fall below the MIN mark when the vehicle is parked in a vertical position ZN WARNING ee If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down In this case consult an authorized KTM dealer immediately Have the brake fluid changed at an authorized KTM workshop every 2 years MAINTENANCE WORK ON CHASSIS AND ENGINE 45 Checking the front brake pads The brake pads can be inspected from the rear The linings must be at least 1 mm 0 04 in thick ZN WARNING SSCS At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed i CAUTION If the brake pads are replaced too late when the lining is partly or completely worn off the steel parts on the brake pads will grind against the brake disks This significantly decreases the braking effect and destroys the brake disks MAINTENANCE WORK ON CHASSIS AND ENGINE 46 Checking the rear brake fluid level The brake fluid reservoir for the rear brake is located on the rear right of the vehicle and has a MIN and a MAX mark The brake fluid level may not fall below the MIN mark when the vehicle is parked in an upright position ZN WARNING OSC If the brake fluid level drops below the minimum either the
31. ND WARNINGS FOR STARTING THE MOTORCYCLE sanci 4 35 schs 4804 hoa oad i we ened 22 Instructions for initial operation 000008 22 Running in the LC8 engine 0 0 cee 22 Accessories and payload 1 cee ee ee ees 23 DRIVING INSTRUCTIONS 000000 e ee eens 24 Check the following before each start 24 Starting the engine 2 1 ee 26 Staring Off sacs eas ones a atarianser iee a a die 27 Shitting Riding wi0 2 4444 24548 6 wane oot wielded dt 27 Brakings sacs id een ots eet oes arte chines qv eee Si mee te a chia 28 Stopping and parking 6 ee 29 FUCl ats Pogue Mabini dears beanie a E E Ad 30 PERIODIC MAINTENANCE SCHEDULE 32 MAINTENANCE WORK ON CHASSIS AND ENGINE 36 Adjusting the fork and shock absorber 37 Adjusting compression damping of fork 37 Adjusting rebound damping of fork 00 37 Adjusting the spring preload on the fork 38 Compression damping of shock absorber 38 Rebound damping of shock absorber 0005 39 Checking the chain tension 00000 eeeeee 40 Correcting the chain tension 00 00 c ee eee 40 Chain maintenance 0000 e eee eee eee 41 Checking the chain for wear 2 00000 cee eee eee 41 General information on KTM disk brakes 42 Adjusting the basic position of the hand brake lever 44 Checking the front brake fl
32. W PROHIBITS THE FOLLOWING ACTS OR CAUSING THEREOF 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing the muffler baffles header pipes or any other components which conducts exhaust gases 2 Removal or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer WARNING STATEMENT This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use Otherwise the owner may become subject to penal ties under state and local ordinances CONSUMER RIGHTS Limited Warranty claims should be directed to an authorized KTM dealer If you are not satisfied please contact KTM North America Inc Customer Relations 1119 Milan Avenue Amherst Ohio 44001 Your rights may vary please refer to the applicable state laws CONSUMER INFORMATION FOR USA ONLY
33. amp M8 12 N HH clamp bolts on bottom triple clamp M8 15 N HH screw for steering head M20x1 5 12 N HH clamp bolts on fork leg axle passages M8 15N Collar bolts for handlebar clamps M8 20 N AH bolt for handlebar mount M10 20N HH clamp bolts for steering stem M8 20 N Collar bolt front rear brake disk M8x1 25 Loctite 243 HH bolts on front brake caliper M10x1 25 Loctite 243 HH bolts on handbrake cylinder M6 HH bolts on footbrake cylinder M6 Loctite 243 1 AH bearing bolt for foot brake pedal shift lever M8 Loctite 243 HH screw on cover plate for foot brake lever shift mechanism M6 Loctite 243 1 Relay for shift shaft on connecting support M8 Loctite 243 Relay for shift shaft on shift shaft M6 Loctite 243 1 Gearshift rod attachment M6 Loctite 243 1 HH bolts on foot brake pedal surface M5 Loctite 243 6 AH bolts for side stand bracket engine Loctite 243 45 31 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 TECHNICAL SPECIFICATIONS CHASSIS TIGHTENING TORQUES CHASSIS 2007 HH bolts for side stand fixture side stand bracket Loctite 243 25 N HH bolts for side stand mounting Loctite 243 35 N HH bolt for spring rest on side stand M8 Loctite 243 25 N HH bolt for side stand switch M4 Loctite 243 2N Drain plug on oil tank M12x1 5 25 N 3433313 Exhaust nuts on manifold M8 eve
34. are not recommended since they can damage the motorcycle s electronic system MAINTENANCE WORK ON CHASSIS AND ENGINE 55 Main fuse The main fuse protects all of the motorcycle s electric power consumers The main fuse is located on the left under the front spoiler Pull the connector 1 out of the bracket remove the cap 2 and check the main fuse 3 A spare fuse 4 30 amperes is also plugged into the bracket Always replace blown fuses with an equivalent fuse Visit an authorized KTM workshop if a new fuse blows again after it is inserted i CAUTION Never use a stronger fuse or a repaired fuse Improper use can destroy the entire electric system MAINTENANCE WORK ON CHASSIS AND ENGINE 56 f i Fuses for individual power consumers i A fuse box is mounted under the seat containing additional fuses that protect the individ ual electric power consumers The power consumers are listed numerically on the cover of the fuse box 1 and allocated as described below Spare fuses 2 with 10 and 15 amperes are also found in the fuse box NO CONSUMER AMPERES ee oo ale ees IOMITIOM siars Saga once 4 Sarda Sed Oa AR De eee de ne eae 10 BE seh ede sci ay doe Light high beam low beam parking light 005 15 Zra Horn brake light combined instrument 0000000 ue 10 Oa sie a es Fuel DUMP mea aeee w ON a pe ms Bead a ASE ada Beaders die a Bos 10 Diacyiea reak PAN aaoi e
35. brake system has a leak or the brake pads are completely worn down In this case consult an authorized KTM dealer immediately Have the brake fluid changed at an authorized KTM workshop every 2 years Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in ZN WARNING OOS At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed i CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn away the steel components of the brake pad will rub against the brake disc imparing the braking effect and destroying the brake disc MAINTENANCE WORK ON CHASSIS AND ENGINE 48 Dismounting and remounting the front wheel Special stands are required to dismount the wheels to make sure the motorcycle is securely fixed The front stand only adequately fixes the motorcycle together with the rear stand The stands shown in the illustration can be found in the KTM Power Parts catalog First mount the rear then the front stand Make sure the stands rest on solid ground and are correctly mounted The front wheel should not touch the ground NOTE FOR SUPER DUKE R First remove the crash pads Remove the screws 1 on the left and right brake caliper and carefully pull the brake cali
36. cables and nipples Bleed fork legs Clean chain Lubricate chain Check chain tension Check tire pressure and wear Check coolant level Check fuel lines for leaks Check all control elements for smooth running Grease the hand brake lever and clutch lever Check brake performance Treat exposed metal components except for the braking and exhaust system with wax based anti corrosion agents Treat ignition steering lock and light switch with contact spray MAINTENANCE WORK ON CHASSIS AND ENGINE 36 i CAUTION Do not clean the motorcycle with a power washer otherwise water will get into the bearings electric socket connectors etc Use special KTM screws with the correct thread length to fasten the spoiler to the tank Mounting other screws or longer screws could puncture the tank and cause fuel to leak out If you disconnect socket connectors with self locking nuts replace them before remounting If no new self locking nuts are available apply Loctite 243 to the thread of the old nuts If the thread is damaged replace the screws and nuts Do not use toothed disks or split washers for the engine fastening bolts since they will work their way into the frame components and become loose Always use self locking nuts Let the motorcycle cool down before servicing to avoid being burned Properly dispose of oils grease filters fuel cleansers etc Observe
37. ce fuse 4 Connect the clutch to the fuel line Remove the panel and fuel tank clean the plug and socket connector and spray with contact spray Visit an authorized KTM workshop Switch to neutral gear Engine will not reach full power Air filter fuel filter heavily soiled Error in the injection system Have the air filter fuel filter replaced at an authorized KTM workshop Visit an authorized KTM workshop Engine overheats Insufficient cooling liquid Radiator fins are extremely dirty Foam forms in cooling system Radiator hose is kinked or damaged Thermostat defective Refill cooling liquid see maintenace work check cooling sys tem for leaks Clean radiator with water jet Replace cooling liquid use antifreezer with brand name Run the radiator hose correctly or replace Have the thermostat checked opening temperature 75 C 167 F or replaced contact an authorized KTM workshop TROUBLESHOOTING 14 TROUBLE CAUSE REMEDY Engine overheats Blown fan fuse Defect fan or thermoswitch for fan Air in the cooling system Replace fuse 5 Contact an authorized KTM workshop Bleed the cooling system see Maintenance work FI lamp is blinking lights up Error in the injection system Visit an authorized KTM workshop Engine stalls while driving No fuel Fuse for fuel pump has blown Refuel Replace fuse 4 High oil consumption Engine oil level too high
38. d actuate the front wheel brake and vigorously com press the fork several times to align the fork legs Before you tighten the clamp screws 3 check whether the right brake disk C runs in the center of the brake caliper Move the right fork leg to the side if necessary then tighten the clamp screws on both fork leg axle passages to 15 Nm Actuate the hand brake until you feel the pressure point and check whether the front wheel can easily be turned Remove the rear stand ZN WARNING OO If you do not have a torque wrench to mount the wheel have the torques corrected by an authorized KTM workshop as soon as possible A loose wheel spindle can cause the motorcycle s handling performance to become instable and cause it to crash After mounting the front wheel keep operating the hand brake until the pressure point returns Always keep the brake disks free from oil and grease otherwise the braking effect will be significantly reduced NOTE FOR SUPER DUKE R remount the crash pads MAINTENANCE WORK ON CHASSIS AND ENGINE 50 Dismounting and mounting the rear wheel Special stands are required to dismount the wheels to make sure the motorcycle is securely fixed The stands shown in the illustration can be found in the KTM Power Parts catalog Mount the rear stand Make sure the stand rests on solid ground and is correctly mounted The rear wheel should not touch the ground NOTE FOR SUPER DUKE R First remove
39. e clutch lever can be modified by turning the adjusting screw 1 This lets you adjust the best clutch lever position for any hand size To adjust pull the clutch lever towards the front Turning the adjusting screw in a clockwise direction will move the clutch lever away from the driver Turning the adjusting screw in a counterclockwise direction will move the clutch lever towards the driver i CAUTION Adjustment of the clutch lever position is only possible within certain limits Only turn the adjusting screw manually and never apply excessive force Checking the oil level of the hydraulic clutch The oil level should be between the MIN and MAX marks with the master cylinder in a horizontal position If necessary add SAE 10 biodegradable hydraulic oil Motorex clutch fluid 75 available from your authorized KTM workshop E CAUTION KTM uses biodegradable hydraulic mineral oil to actuate the hydraulic clutch Do not mix this oil with any other hydraulic oil Always useoriginal KTM hydraulic oil available from your authorized KTM workshop to make sure your clutch operates smoothly Never refill with brake fluid Adjusting the handlebar tilt Loosen the screws 2 Adjust the handlebar and tighten the screws to 20 Nm Make sure the handlebar instruments do not touch the fuel tank when the handlebar is com pletely turned A Tilting the handlebar too far back will reduce the steering angle since the handlebar instr
40. e life To charge the battery while mounted always use the KTM battery charger Item no 58429074000 to ensure that the electric system is not damaged by excess voltage Always remove the battery if using other battery chargers You can also use this charging device to test the off load voltage and startability of the battery and generator It is impossible to over charge the battery with this device Charge the battery immediately if it is empty when you start the motorcycle If left to stand in an uncharged condition for a longer period of time the battery will run down and sulfa tize destroying the battery Recharge the battery every 3 months if it is being stored for a longer period of time E CAUTION Never remove the closure since it will be damaged To avoid damage to the on board electronic system always disconnect the minus pole before you charge the battery To charge connect the battery to the battery charger before you switch on the battery charger When the battery is charged switch off the battery charger before you discon nect the battery Provide adequate ventilation when charging the battery in a closed room the battery emits explosive gases when charging Electrolytes will escape through the safety valves if the battery is charged too long or at an excessive voltage or amperage This will reduce battery capacity Try to avoid quick charges Jump start Jump starts
41. e service manual to avoid losing your right to claim under the warranty The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the motorcycle AUTOMOTIVE FLUIDS The fuels lubricants and liquids specified in the Owner s Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule SPARE PARTS ACCESSORIES For your own safety only use spare parts and accessories approved by KTM KTM shall not assume any liability for other products or consequential damage resulting from the use of such products ENVIRONMENT Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full It may however involve potential problems for the environment or lead to conflicts with others These problems or conflicts can be avoided if the motorcycle is used responsibly To safeguard the future of motorcycle sports make sure that you use the motorcycle in accordance with the law show that you are environmentally conscious and respect the rights of others Enjoy driving your motorcycle KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA INDEX INTRODUCTION erans dee dard ta Bae pagal ete ab 1 IMPORTANT INFORMATION 000 0000 eeeeee 2 SERIAL NUMBER LOCATIONS 00000 eee eee 6 Chassis number Type label 2 0 0 0 eee ee 6 Engine number engine type 00 00 eee eee 6 OPER
42. e the headlight range CONTROL Make a mark on a light colored wall behind a horizontal surface at the height correspon ding to the center of the headlight Position your motorcycle 5 meters 16 4 ft from the 5m wall in a fully loaded condition baggage driver passenger and switch on the low beam The light dark cut off should be 5 cm 2 in under the mark see drawing 5cm MAINTENANCE WORK ON CHASSIS AND ENGINE 59 Replacing the brake light and taillight bulbs NOTE Only mount red light bulbs in a smoked brake tail light Remove the seat BULB FOR BRAKE LIGHT Turn the bulb socket 1 approx 30 in a counterclockwise direction and pull it out of the taillight housing Slightly press in the bulb turn approx 30 in a counterclockwise direc tion and remove it from the socket Proceed in the reverse order to mount a new bulb BULB FOR THE TAILLIGHT Remove the bulb socket 2 from the housing and pull the bulb out of the socket Insert a new bulb and press the bulb socket all the way into the taillight housing Mount the seat Replacing the flasher bulbs Remove the screw on the back of the turn signal carefully fold the lens 3 towards the motorcycle and remove Slightly depress the bulb turn it approx 30 counterclockwise and pull it out of the socket To mount the lamp reverse the worksteps indicated above MAINTENANCE WORK ON CHASSIS AND ENGINE 60 ec C
43. ed Tires will not display their full grip char acteristics until they are properly run in Wheels with a different rim diameter or other rim width may not be mounted oth erwise the vehicle handling will no longer be safe Observe the traffic regulations drive defensively and trying to look ahead as far as possible so that any hazards can be recognized as early as possible The faster you drive the more sensitive your motorcycle will be to crosswind and changing road conditions Your motorcy cle can easily go out of control at high speeds Choose your driving speed according to the conditions and your driving skills Drive carefully on unknown roads or on unfamiliar trials Renew the vizor on your helmet on time so as to ensure optimum vision in any sit uation When light shines directly on scratched visor the operator will be blinded You may only be accompanied by a pas senger if your motorcycle is fitted and reg istered for such purposes Never leave your motorcycle without super vision if the engine is running Accessories and payload Accessory parts and baggage can signifi cantly decrease a motorcycle s driving stabil ity Please observe the following warnings AE Never drive faster than 130 kph 80 mph if you have mounted accessory parts on your motorcycle Accessory parts can sig nificantly impair the motorcycle s han dling especially in the maximum speed range Never drive faster than 130 kph 80
44. eep the battery poles clean and slightly grease them with an acid free grease if necessary The charge condition and type of charge are very important for the battery s service life UN WARNING Never operate the motorcycle with a run down battery or without the battery This can dam age the electronic components or safety equipment in either caseand the motorcycle will no longer be roadworthy E CAUTION Never remove the closing cover 1 otherwise the battery will be damaged MAINTENANCE WORK ON CHASSIS AND ENGINE 53 Removing and remounting the battery The battery only needs to be removed if the motorcycle is being immobilized Remove the screws 1 on both sides loosen the screws 2 2 turns and remove the front spoiler towards the front Push the cables to the side Remove the screws 3 and fold the battery cover 4 down First disconnect the negative terminal then the positive terminal from the battery Make sure the battery terminals are not bent when they are removed Remove the battery cover and take out the battery Charge the battery before and after storage Storage temperature O 35 C 32 95 F When remounting the battery position it in the battery compartment and mount the battery cover First connect the cables on the positive terminal then connect the negative terminal to the battery to avoid a short circuit Open the battery cover and fasten with 2 screws Remount t
45. emperature display 0005 12 Battery ctctrtcatan ma e ss Ganeaoen an eRe ena es 52 Cooling System coi dso ses abated A eae oa tia oS 60 Bleeding the cooling system 1 ee ee 62 Correcting the chain tension 0 cee eee 40 Braking a fu oft cite mes batten aie went At Ranta Mee tech 28 Damping action during compression of shock absorber 20 Chain maintenance sce avai aoe ott eh tere fae A 41 Dismounting and mounting the rear wheel 50 Changing the basic position of the clutch lever 64 Dismounting and remounting the front wheel 48 Changing the engine oil and the oil filter Driving instructions 2 0 ae a A eee 24 cleaning the oil screen nananana naaa eee 68 Engine number engine type 0 0 00 eee eee 6 Charging the battery 0 cece eee 54 SENSING OM aienea ey el oy tN EA A AE Doce OE BY 84 Chassis number Type label 1 0 c eee ees 6 JENgineOll Sad as acted dickens anaes mene 66 Check the following before each start 05 24 FiO Capra i i eats is Me 49 54 SSeS D4 Shad a et we bie t 15 Checking the chain for wear 0 0 cece ee eee 41 Foot brake pedal nonan anaana 18 Checking the chain tension 0 0 00 eee eee eee AQ RootrestS TA aae deel ee ee ah ea ana ee 19 Checking the cooling liquid level in the compensating tank 61 Fuel 2 ee eee ee 30 Checking the cooling liquid level in the radiator
46. ent brake pads than those provided with the original equipment it cannot be warranted that they are authorized for use in road traffic Your motorcycle will not longer comply with the regulations authorizing the use of vehicles for road traffic and the warranty will be void BRAKE FLUID RESERVOIRS The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid There is no reason to remove the reservoir cap under normal conditions If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are com pletely worn down In this case consult an authorized KTM dealer immediately MAINTENANCE WORK ON CHASSIS AND ENGINE 43 BRAKE FLUID We recommend that you use Motorex DOT 5 1 brake fluid when you refill or change the brake fluid DOT 5 1 brake fluid has a wet boiling point of 180 C 356 F 25 C 45 F higher than DOT 4 and is safer for high performance applications Brake fluid DOT 5 1 is a poly ethylene glycol based fluid amber colored and can be mixed with DOT 4 brake fluid Do not in any event use DOT 5 brake fluid It is based on silicone oil and is dyed purple KTM motorcycle gaskets and brake hoses are not designed for DOT 5 brake fluid Brake fluid is exposed to a high thermal load and absorbs moisture from the air which low er
47. ent and sponge Coarse dirt can be removed with a soft water jet Areas that are heavily soiled can be sprayed with a motorcycle cleaner e g Motorex 900 and cleaned with a brush After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Then take a short drive until the engine has reached the working temperature and also use the brakes Due to the heat the water also evaporates at the unapproach able parts of the engine and the brakes After the motorcycle has cooled down oil or lubricate all of the friction bearings and bearing positions and treat the chain with chain spray Treat all bare areas except brake disks with a corrosion inhibitor e g Motorex Protect amp Shine The exhaust pipes and mufflers are made of stainless steel and should be treated with a suitable care product To prevent failures in the electric system you should treat the ignition lock the emergency OFF switch light switch and the socket con nectors with contact spray Treat all of the painted parts with a mild paint care product e g Motorex Moto Polish CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take precautions against the aggressive road salt clean motorcycle thoroughly and let it dry treat engine swing arm and all other bare parts except for brake discs with a
48. et a a ae ee Wee dw ed ee an ea ea 2 ee aed 10 Or hxe en wad GIOCK satiate apace sake Saree arate eons PaceeE steed Has aed Bae a eee oa 10 T pei pia Aaen Main relayo seia dale niuda ow dha dele Be oe awa a ee ened 10 Bleed a ele n ACC1 for attachments switched with the ignition 10 e awl bee e a ACC2 for attachments positive supply 0 eee ees 10 LO iia SPARE Spare fuses 5 25 cc cpp gtee exces we eee ects use de oeteeece sage asses Oe 10 15 Replace a blown fuse only with an equivalent one If a new fuse that has just been set in gets blown again you are strongly advised to have it inspected by a KTM dealer 1 CAUTION Under no circumstances is a stronger fuse allowed to be set in or a fuse allowed to be repaired An inexpert treatment could damage the whole electrical installation The ACC1 and ACC2 fuses 3 are designed for attachments with a maximum power con sumption of 10 amperes The respective connector for this equipment is located in the head light mask Ask your authorized KTM workshop for details MAINTENANCE WORK ON CHASSIS AND ENGINE 57 Replacing the headlight lamp Remove the screws 1 on the left and right and tilt the headlight mask down towards the front E CAUTION Never touch the glass of the bulb with your fingers The glass of the bulb must remain absolutely free from grease Heat will otherwise cause the grease to evaporate and settle down on
49. ey 1000 km or or once a year every 2 years Change engine oil and oil filter e e Clean oil screens of engine and oil tank e Clean magnetic drain plugs of engine and oil tank e Check oil lines for damage and kink less arrangement e Renew spark plugs Check and adjust valve clearance Check engine fastening bolts for tight fit Check all engine bolts accessible from the outside for tight fit Check clutch linings Check clutch pressure booster system Clean the oil jet for the clutch lubrication Check rubber boots for cracks or leaks Check fault memory with the KTM diagnosis tool Perform a status check of neutral clutch 2nd 3rd gear and side stand switch using the KTM diagnosis tool Make sure the fuel hose hoses on the vacuum sensors SAS hoses and vent hoses are run correctly and check for damage Replace the O ring on the fuel hose connection and check for leaks Check the wiring harness on the throttle body for proper installation and damage Check cooling system for leaks and antifreeze protection FUEL INJECTION Check radiator fan for proper operation Check the exhaust system for leaks and correct suspension and the clamps for a tight fit PERIODIC MAINTENANCE SCHEDULE 990 SUPER DUKE R 2007 A clean motorcycle can be checked more quickly which saves money 1st Service after 1000 km every 7500 km or once a year every 15000 km o
50. fuel in the tank Inspect the motorcycle as you would before each start up see Driving Instructions Goon a short cautious test ride NOTE before you store your motorcycle at the end of the season check all parts for proper functioning and wear If service repairs or con versions are necessary have them carried out while the motorcycle is immobilized workshops are not fully utilized This will help to avoid long waiting periods at the beginning of the season TECHNICAL SPECIFICATIONS CHASSIS 79 CHASSIS 990 SUPER DUKE R 2007 Frame Tubular chrome molybdenum steel space frame Fork WP Suspension Up Side Down 4860 ROMA Spring travel front 135 mm 5 3 in Rear suspension WP Suspension 4618 BAVP Spring travel rear Super Duke 160 mm 6 3 in Super Duke R 150 mm 5 9 in Front brake Disk brake 2 perforated brake disks 320 mm 12 6 in brake calipers radially bolted Rear brake Disk brake perforated brake disk 240 mm 9 4 in floating brake caliper Authorized front tires DUNLOP Sportmax D208 RR 120 70 ZR17 M C 58W Air pressure front Road driver only si erel iee ate aa iaa 2 4 bar Road with passenger maximum payload 2 4 bar Authorized rear tires DUNLOP Sportmax D208 RR 180 55 ZR17 M C 73W Air pressure rear Road driver ONY cccceeccecceeeeecceeeceeeeeeeeeneees 2 4 bar Road with passenger maximum pay
51. g Tighten the screws to 6 Nm E CAUTION Only use original ktm oil filters The engine can be damaged if other filters are used Mount the oil drain plug on the oil tank with a new seal ring and tighten to 20 Nm Grease the seal ring 4 and carefully slide the oil screen into the oil tank Position the oil return valve 5 mount the screws and tighten to 10 Nm MAINTENANCE WORK ON CHASSIS AND ENGINE 11 Remove the right spoiler see Refilling the engine oil and unscrew the plug 6 Add 2 5 liters 0 7 USgal of fully synthetic engine oil meeting the JASO MA standard e g Motorex Power Synt 4T and remount the plug Start the engine and allow to run warm in neutral until 4 bars on the temperature indicator light up Switch off the engine and check the oil level see Checking the engine oil level Check the engine and the oil tank for oil leakage Fit the slots in the front spoiler on the lower screws 7 and tighten Apply Loctite 243 to the side screws 8 and tighten to 10 Nm Finally mount the spoiler see Refilling the engine oil TROUBLESHOOTING 12 If you have your motorcycle serviced as set forth in this manual no malfunctioning is to be expected Nevertheless if an error does arise we recommend that you look for the error according to the following chart Please note that you cannot perform all of the work yourself If you are not sure contact your KTM dealer TROUBLE CAUSE R
52. g lamp 4 should go out as soon as the engine is running 6 Take the load off the side stand and fold the side stand all the way up ZN WARNING eC Do not start the engine and allow it to idle in a closed room Exhaust fumes are poison ous and can cause loss of consciousness and death Always provide adequate ventila tion while the engine is running Never operate the motorcycle with a run down battery or without the battery This can damage the electronic components or safety equipment in either caseand the motorcy cle will no longer be roadworthy 1 CAUTION If you accelerate while starting the engine management will not inject any fuel and the engine will not start Do not accelerate while starting If the oil pressure warning lamp does not go out as soon as the engine is running imme diately switch off the engine If the engine is not switched off engine damage will occur within a short period of time Check the engine oil level or contact a ktm workshop Maximum period for continuous starting 5 seconds Wait at least 5 seconds before try ing again Don t ride your motorcycle with full load and don t rev engine when cold Because the piston is warming up faster than the water cooled cylinder it can cause engine damage Always let the engine warm up before and refrain from driving with full load until the engine is warm DRIVING INSTRUCTIONS 21 IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE
53. g liquid is leak ing out of the motorcycle Check the cool ing liquid level in the radiator not only in the compensating tank CAUTION SCALDING HAZARD Do not drive on until there is sufficient liquid in the col ing system In the event that while riding on your motorcycle you notice any unusual oper ation related noise stop immediately turn the engine off and contact an author ized KTM dealer Braking Close throttle and apply the hand and foot brakes at the same time Carefully apply the brakes on sandy wet or slippery surfaces Always brake with feeling blocking wheels can cause you to skid or fall Also change down to lower gears depending on your speed Always finish braking before you enter a curve When driving downhill use the braking effect of the engine Change down one or two gears but do not overspeed the engine In this way you will not need to brake so much and the brakes will not overheat ADT as In the rain or after the motorcycle has been washed braking action may be delayed due to wet brake discs First the brakes must be braked dry DRIVING INSTRUCTIONS 29 AE On salt sprayed or dirty roads brake action may be delayed as well First the brakes must be braked clean Remember that the stopping distance will be longer if you are carrying a pas senger or baggage When you brake the brake discs brake pads brake caliper and brake fluid heat up The
54. h bar on the temperature indicator lights up If the red oil pressure warning lamp lights up while driving the oil pressure is too low to adequately lubricate the engine Stop immediately and switch off the engine if you continue to drive engine damage will occur within a short period of time Check the engine oil level or con tact an authorized KTM workshop Never have the throttle wide open when changing down to a lower gear The engine will overspeed damaging the valves In addition the rear wheel blocks so that the motorcycle can easily get out of control Never use your motorcycle without an air filter Otherwise dust and dirt may enter the engine and cause increased wear Stop immediately if a perceptible power loss occurs while driving due to a defec tive ignition caused by a cylinder misfir ing or breaking down If the unburned fuel air mixture reaches the catalytic con verter it will ignite and the resulting heat will destroy the catalytic converter and the adjoining components The red coolant warning lamp lights up when the coolant temperature has reached 120 c 248 F Possible causes for the increase in tem perature low driving velocity and high load sit uation in high air temperatures level of coolant in the system is insuf ficient fan at radiator is not running improper use of the clutch while driving at low velocities Let the engine cool down Meanwhile check whether any coolin
55. he front spoiler Apply Loctite 243 to the screws 1 and tighten to 10 Nm MN WARNING ee If electrolyte sulphuric acid leaks from the battery proceed with great care The elec trolyte can cause severe burns In the case of skin contact rinse thoroughly with water Inthe case of contact with the eyes thoroughly rinse eyes with water for at least 15 min utes Immediately consult a doctor The battery is a closed model but can nevertheless emit explosive gases Avoid sparks and open fire near the battery Defective batteries must be stored out of the reach of children Ensure proper disposal of discarded batteries The screws on the underride protection must be secured with loctite 243 to prevent them from becoming loose 1 CAUTION Never disconnect the battery while the engine is running This will destroy the rectifier reg ulator STORAGE If the motorcycle is being immobilized for longer periods of time remove and charge the battery Storage temperature O 35 C 32 95 F avoid direct sunlight Charge the battery every 3 months MAINTENANCE WORK ON CHASSIS AND ENGINE 54 Charging the battery The battery discharges every day even if it is not used Always disconnect the battery when charging Charge the battery as described in the instruc tions 1 on the battery housing Do not exceed the amperage and charging time Quick charg ing at a high amperage has an adverse effect on the servic
56. he removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorpo rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality REG NO 12 100 6061 IMPORTANT INFORMATION INTENDED PURPOSE The 990 Super Duke is designed to resist the usual wear and tear of paved roads but is not designed for race courses or off road use The 990 Super Duke R is designed to resist the usual wear and tear of paved roads or race courses but is not designed for off road use OWNER S MANUAL Carefully read the entire Owner s Manual before you start riding your motorcycle even if this will take a little time It contains use ful tips and information on the best way to handle the motorcycle and how to protect yourself from injuries The Manual also con tains important information on service and maintenance In your own interest pay particular attention to the information marked as follows ADT es CAUTION Ignoring these instructions can endanger your body and Ignoring these instructions could cause da
57. hold on to the holding strap 4 or the driver while riding OPERATION INSTRUMENTS 18 Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear The basic position of the shift lever can be adjusted according to your seating position see Maintenance work Side stand Fold the side stand 1 forward to the stop with your foot and put the weight of the motor cycle on the stand Make sure it is standing securely on a firm surface The side stand is linked to the safety start system follow the driving instructions Foot brake pedal The foot brake pedal 2 is located in front of the right footrest Its basic position can be adjusted to your seat position OPERATION INSTRUMENTS 19 Footrests The passenger footrests 1 fold up Compression damping of fork The fork s damping action during compression travel compression damping can be adjusted This allows you adjust the damping behavior to match your driving style and the payload The adjusting screws 2 are located on the fork leg axle passage More information is provided in the chapter Adjusting the fork and shock absorber Rebound damping of fork The fork s damping action during rebound travel rebound damping can also be adjusted This allows you adjust the damping behavior to match your driving style and the payload
58. hotter these parts get the weaker the braking effect In extreme cases the something is wrong with the brake sys tem Don t ride your motorcycle anymore without first having the brake system looked over by a KTM dealer entire braking system can fail If the resistance in the hand brake lever or foot brake pedal feels spongy too much play this is an indication that Stopping and parking Apply the brakes fully and put the engine into neutral To stop the engine switch off the ignition Fold the side stand forward to the stop with your foot put the weight of the motor cycle on the stand and park the bike on a firm surface Lock the motorcycle ZN WARNING OOS always park your motorbike on a solid and horizontal surface Never leave your motorcycle without supervision as long as the engine is running Motorcycle engines produce a great amount of heat while running The engine radiators exhaust exhaust system brake discs and shock absorbers can become very hot Do not touch any of these parts after operating the motorcycle and take care to park it where pedestrians are not likely to touch it and get burned Never park your motorcycle in places where there exist fire hazards due to dry grass or other easily flammable materials CAUTION Always take out the ignition key when parking your motorcycle so that it cannot be used by unauthorized persons The side stand is dimensioned for the weight of the motorcycle only Sit
59. ill light up for 1 second for the function test LENGTH The display will change for 1 second to display the circumference of the front wheel in mil limeters 1870 mm corresponds to a 17 front wheel Then the display will change back to the mode that was activated when the ignition was switched off OPERATION INSTRUMENTS 9 SPEED 1 The speed can be displayed in kilometers per hour km h or miles per hour mph CHANGING THE SPEED DISPLAY FROM KM H MPH or MPH KM H Switch on the ignition and press the MODE button more than 10 seconds in the ODO mode CLOCK 2 The dots between the hours and minutes will blink in the CLOCK display The clock must be set if the battery was disconnected or if the fuse 6 was blown SETTING THE CLOCK Switch on the ignition and select the ODO mode Press and hold the MODE button while you press the SET button more than 1 second The time will start to blink Use the MODE button to set the hours Use the SET button to set the minutes Then press the MODE and SET buttons simultaneously AMBIENT TEMPERATURE 3 The ambient temperature can be displayed in Celsius C or Fahrenheit F CHANGING THE AMBIENT TEMPERATURE DISPLAY FROM C F or F C Switch on the ignition and press the MODE button more than 10 seconds in the ambient temperature mode Press the MODE button to go to the next display mode OPERATION INSTRUMENTS 10 FROST WARNING
60. ion bearing Piston pin bearing Dual fuel bearing Piston Light alloy forged Piston rings 1 compression ring 1 taper face ring 1 single piece oil scraper ring with spiral type expander Engine lubrication Dry sump with 2 trochoidal pumps pressure pump and suction pump Engine oil SAE 10W 50 Motorex Power Synt 4T Quantity of engine oil approx 3 liters 0 8 USgal during oil filter change Primary drive Straight toothed spur wheels 35 67 Clutch Multi disc clutch in oil bath Transmission 6 speed claw shifted Gear ratio 1 gear 14 36 2 gear 16 30 3 gear 20 30 4 gear 21 27 5 gear 23 26 6 gear 25 26 TECHNICAL SPECIFICATIONS ENGINE 84 ENGINE 990 LC8 2007 Ignition system breakerless transistorized electronic ignition system with digital ignition advance Ignition timing Map controlled via TPS Map controlled via TPS 12V 450W at 6000 rpm Spark plug NGK IR KR8BI Electrode distance 0 8 mm Cooling system liquid cooled permanent circulation of cooling liquid through water pump Cooling liquid 2 1 liters 0 55 USgal 50 antifreeze 50 distilled water at least 25 C Starting aid electric starter x PON CLC RON ROZ 87 91 JASO T903 MA 91 Premium 95 PON Pump Octane Number TEMPERATUR CLC Cost of Living Council 0 C RON Research Octane Number 32 F ROZ Research Oktan
61. le may lead to an unstable driving behavior of your motorcycle After mounting the rear wheel keep operating the footbrake until the pressure point returns It is very important to keep the brake disk free from oil and grease otherwise the brak ing effect would be strongly reduced Tires air pressure Tire type tire condition and how much air pressure the tires have in them affect the way your motorcycle rides and they must therefore be checked whenever you re getting ready to go anywhere on your motorcycle UN WARNING For driving safety and maximum handling only use tires authorized by KTM tire releases are available on the Internet at www ktm com corresponding to the ZR speed index over 240 KPH Other tires can have a negative effect on the motorcycle s handling e g can cause it to wobble at higher speeds MAINTENANCE WORK ON CHASSIS AND ENGINE 52 Tire type and size can be found in the technical specifications and in the homologation certificate front Tire condition has to be checked every time you want to ride your motorcycle Before 2 4 bar leaving check for punctures and nails or other sharp objects that might have become embedded in the tire 34 psi Refer to the specific regulations in your country for minimum tire tread requirements Road with passenger 2 4 bar We recommend replacing tires at the latest when the tread is down to 2 mm 0 08 in 34 psi Tire pressure
62. load 2 6 bar Fuel tank capacity 18 5 liters 4 9 USgal 3 5 0 9 USgal liters Reserve Gear ratio rear wheel 17 38 Chain 5 8 x 5 16 X ring Lighting high beam H3 12V 55W socket PK22s H7 12V 55W socket PX26d H4 12V 60 55 W socket P43t 12V 5W socket W2 1x9 5d USA high beam low beam position light front indicator lamps position light rear USA position light rear 12V 5W socket W2 1x9 5d stoplight 12V PR21W socket BAW15s USA stoplight 12V 21W socket BA15s flashers 12V RY10W socket BAU 15s licens plate illumination 12V 5W socket W2 1x9 5d 12V WR5W socket W2 1x9 5d Super Duke R LED Super Duke R LED Super Duke R LED Super Duke R LED further tire releases are available on the Internet at www ktm com TECHNICAL SPECIFICATIONS CHASSIS CHASSIS 990 SUPER DUKE R 2007 Battery maintenance free battery 12V 11 2 Ah Steering head angle Super Duke 66 1 Super Duke R 67 3 Wheel base 1450 10 mm 57 0 4 in Seat height unloaded Super Duke 850 mm 33 5 in Super Duke R 860 mm 33 9 in Ground clearance unloaded Super Duke 140 mm 5 5 in Super Duke R 150 mm 5 9 in Dry weight 186 kg 410 6 Ibs Max axle load front 180 kg 397 3 Ibs Max axle load rear Max total load BASIC SETTING FORK WP 4860 ROMA 250 kg 551 8 Ibs 387 kg 854 2 Ibs Super Duke S
63. mage to parts your life of your motorcycle or that the motor cycle is not road safe anymore The Owner s Manual corresponded to the latest information available for this model series at the time it was printed Minor devia tions resulting from enhancements to the motorcycle design cannot be entirely precluded The Owner s Manual is an integral part of the motorcycle and must be handed over to the new owner when the motorcycle is sold SERVICE Observance of the service maintenance and operating instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear Please observe the prescribed breaking in periods inspec tion intervals and service intervals Strict observance will significantly prolong the service life of your motorcycle The use of the motorcycle under extreme conditions e g on the race course can cause above average wear to components such as the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the main tenance schedule has been reached IMPORTANT INFORMATION WARRANTY The service work specified in the Lubrication and Maintenance Schedule must be performed by an authorized KTM workshop This is the only place that has the qualified technicians and the special tools required for the 990 Super Duke R Be sure to have the workshop verify all service work carried out in th
64. mph if your motorcycle is loaded with cases or other baggage They will impair the motorcycle s handling at higher speeds and can easily cause it to go out of control If you have cases mounted do not exceed the manufacturer s recommended maxi mum payload Four loops are provided on the bottom of the seat to attach your luggage Make sure your luggage does not extend beyond the silencer otherwise it may become singed from the heat Make sure your luggage does not cover the tail light Baggage must be securely and adequately fastenend loose baggage will significantly impair driving safety A high payload will change the motorcy cle s handling and considerably increase the braking distance adapt your driving speed accordingly Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is made up of the following components Motorcycle ready for operation and tank full Luggage Driver and passenger with protective clothing and helmet DRIVING INSTRUCTIONS 24 Check the following before each start When you start the motorcycle must be in perfect mechanical condition For safety reasons you should make a habit of performing an overall check of your motorcycle before each start The following checks should be performed 1 FUEL Check the fuel quantity in the tanks 2 CHAIN Check the tension and condition of the chain A loose chain can fall off
65. nd the engine oil in it is very hot do not burn yourself Park the motorcycle on an even surface in an upright position Place a vessel under the engine to catch the used oil and remove the oil drain plug 1 Remove the oil drain plug 1 take off the cap 2 and pull the oil sieve out of the engine case with a pair of pliers Remove the oil filter cover 3 and pull the oil filter out of the engine case with circlip pli ers upside down Remove the screws 4 loosen the screws 5 by 2 turns and remove the front spoiler towards the front MAINTENANCE WORK ON CHASSIS AND ENGINE 69 Remove the drain plug 6 on the oil tank and allow the oil to drain into a receptacle Remove the screws 7 and tilt the oil return valve 8 to the side Carefully pull the oil screen 9 out of the oil tank Thoroughly clean the drain plugs the cover and both oil screens Clean all rubber seal rings and check for damage Replace if necessary MAINTENANCE WORK ON CHASSIS AND ENGINE 70 Y n rr Mount the oil drain plug on the engine with a new seal ring and tighten to 20 Nm Slide the oil screen 1 into the guides in the oil pump housing with the TOP mark fac ing up Make sure the form ring is in place and mount the cap 2 Tighten the screws to 10 Nm Insert a new oil filter 3 in the engine case grease the O ring and mount the oil filter cover together with the O rin
66. ndi cated in the tachometer Exceeding the above listed rotations as well as pushing high rpm when the engine is cold will have an adverse effect on the life of your engine AN WARNING as Wear suitable clothing when driving a motorcycle Clever KTM drivers always wear a helmet boots gloves and a jacket regardless of whether driving all day or just for a short trip The protective cloth ing should be brightly colored so that other vehicle can see you as early as possible Your passenger will also need suitable protective clothing Do not drive after having consumed alcohol Always turn on the light to make sure that other drivers become aware of you as early as possible Drive at a moderate speed for the first few kilometers of each trip to allow the tires to reach the necessary operating temper ature Maximum road grip is assured when the tires are warm The front and rear wheel are allowed to be fitted only with tires that have the same profile type GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 23 AE The tires must be designed for a speed of over 240 KPH speed symbol ZR and must be released by KTM New tires have a smooth surface which means that they must be run in to achieve full grip For this purpose ride the motor cycle carefully at moderate speed during the first 200 kilometers with new tires tilting the vehicle at different angles so that all sections are properly roughen
67. nly do not bend sheet met D Exhaust clamps M8 8N Exhaust clamps for ball joint M8 35 N AH bolts on tank cover M5 5N HH bolts on tank mounting M6 6N Collar screws for in tank pump M6 6N AH screw on arm for tank support 15 N Collar screw for gas pressure shock absorber M6 6N Seat fixing plate M5 4N HH nut for seat lock M19x1 8N Jerk damper bolt rear wheel M10x1 25 Loctite 243 50 N Chainguard M5 5N Chain sliding guard M5 5N Front spoiler Loctite 243 10 N Taillight 8N Other bolts on chassis 10 N 25 N 45N Other collar nuts on chassis 15 N 30 N 50 N 333 333 3 3 3 3 3 3 3 3 3 3 3 3 3 3 TECHNICAL SPECIFICATIONS ENGINE 83 ENGINE 990 LC8 2007 Design Liquid cooled 2 cylinder 4 stroke engine with 75 V arrangement with balancer shaft and electric starter Displacement 999 cc Bore Stroke 101 62 4 mm Compression ratio 11 5 1 Fuel unleaded fuel with at least RON 95 USA Premium RON 91 Valve timing 4 valves controlled over bucket tappet and 2 camshafts camshaft drive with gears chain Valve diameter Intake 38 mm Exhaust 33 mm Valve clearance cold Intake 0 10 0 15 mm Exhaust 0 25 0 30 mm Crankcase bearing Friction bearings 2 main bearings 1 supporting bearing Conrod bearing Frict
68. nning when the cooling liquid temperature is 120 C 248 F and the ignition is on If the fan is not working and there appears to be sufficient cool ing liquid the only thing you can do is to drive on to your nearest authorized KTM work shop at the least possible engine load Too little cooling liquid in the system Check whether any cooling liquid is leaking out also on the bottom of the motorcycle Let the engine cool down and check the cooling liquid level in the radiator see chapter Checking the cooling liquid level in the radiator Only continue to drive if there is enough cooling liquid in the system Contact an authorized KTM workshop to have the error elim inated You will damage the engine if you continue to drive when the cooling liquid tem perature warning lamp is on Excessive use of the clutch at slow speed MAINTENANCE WORK ON CHASSIS AND ENGINE 61 A mixture of 50 antifreeze and 50 distilled water is used as the cooling liquid How ever the anti freeze protection must be at least 25 C 13 F Aside from antifreezing pro tection this mixture also provides great corrosion protection which is why it must not be replaced by pure water 1 CAUTION For the cooling system use only high grade antifreezer Motorex Anti Freeze Using lowergrade antifreeze agents can cause corrosion and coolant foaming More antifreeze must be added if you plan to travel to a region where tempera
69. nt to both fork legs STANDARD ADJUSTMENT Turn adjusting screw clockwise as far as it will go Super Duke Turn 15 clicks in a counterclockwise direction Super Duke R Turn 18 clicks in a counterclockwise direction Adjusting rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound By turning the adjusting screw 2 REB the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping dur ing rebounding Make the same damping rate adjustment to both fork legs STANDARD ADJUSTMENT Turn adjusting screw clockwise as far as it will go Super Duke Turn 15 clicks in a counterclockwise direction Super Duke R Turn 16 clicks in a counterclockwise direction MAINTENANCE WORK ON CHASSIS AND ENGINE 38 Adjusting the spring preload on the fork The fork spring preload can be adjusted by turning the adjusting screws 2 wrench size 24 mm 5 mm 0 2 in Turning in a clockwise direction will increase the preload turning in a counterclockwise direc tion will decrease the preload 1 turn will change the preload by 1 mm Changing the preload will not affect the rebound damping adjustment although adjusting screw 1 will turn at the same time Make the same spring preload adjustments to both fork legs Generally if the preload is higher the rebound damping should also be set higher ST
70. o auto matically reset to O and to return to the previous display mode NOTE Press the SET button for 2 seconds to switch off the fuel warning lamp OPERATION INSTRUMENTS 12 wr we max eye ew normally normalemente normal A normalment normalmente kalt cold freddo froid fr o Cooling liquid temperature display The temperature display 1 is shown in 12 bars The more bars that light up the hotter the cooling liquid When the upper bar lights up 120 C 248 F all of the bars will start to blink and the red warning lamp 2 will light up UN WARNING Possible causes for an increase in temperature causing the red warning light for the cool ing liquid temperature to light up Driving too slowly and driving with a heavy load at high air temperatures Not enough cooling liquid in the system The ventilator on the left radiator is not running Improper use of the clutch when driving slowly Tachometer The tachometer 3 shows the engine speed in revolutions per minute Do not run the engine beyond the orange mark at 9500 rpm The speed limiter will set in at 9600 rpm drastically reducing the engine power above this rotational speed OPERATION INSTRUMENTS 13 Ean PA tax Indicator lamps e X The green indicator lamp will blink in the blinker rhythm when the blinker is N switched on 2a NOTE The indicator lamp will blink slower when a blinker is broken On
71. ooling system The water pump in the engine ensures a forced circulation of the cooling liquid When the engine is cold the cooling liquid only circulates in the cylinders and cylinder heads The thermostat will open when the engine reaches approx 75 C 167 F and the cooling liquid will also be pumped through the aluminum radiator Cooling is by means of the air stream The lower the speed the lower the cooling effect Soiled cooling fins also impair the cooling effect If for example slow urban traffic or waiting at a traffic light cause little or no air to stream through the radiator the temperature of the cooling liquid will rise The radiator fan 1 switches on when the cooling liquid reaches a temperature of 102 C 216 F Additional air is blown through the radiator to prevent the cooling system from overheating 1 CAUTION The temperature indicator 2 will begin to blink and the red cooling liquid temperature warn ing lamp 3 will light up when the cooling liquid reaches approx 120 C 248 F having exceeded the normal operating temperature Possible causes Slow riding with large loads at a higher air temperature If possible increase your running speed so that more air can blow through the radiators Should the warning light still be on off after 1500 meters 1 mile stop immediately switch off the engine and look for other possible causes The cooling fan on the radiator is not working The cooling fan must be ru
72. ou are not braking If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated Do not make any alterations to the motor cycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle New tires have a smooth surface which means that they must be run in to achieve full grip For this purpose ride the motor cycle carefully at moderate speed during the first 200 kilometers with new tires tilting the vehicle at different angles so that all sections are properly roughened Tires will not display their full grip char acteristics until they are properly run in Motorcycles are sensitive to changes in the weight distribution Read the section on Accessories and payload when car rying luggage Pay attention to running in procedure Running in the LC8 engine Even finely machined surfaces of engine parts have rougher surfaces than parts that slide on each other for a long time Therefore every engine must be run in For this reason do not demand maximum performance from the engine for the first 1000 kilometers 620 miles The vehicle must be run in at low changing performance level for the first 1000 km 620 miles The maximum number of revolutions per minute must not go exceed 6500 rpm Once you have run your engine in for 1000 km you may push it to its 9500 rpm limit i e up to the orange zone i
73. pers and bushings 6 off the brake disks towards the back Loosen the collar screw 2 and the clamping screws 3 on both fork leg axle passages Unscrew the collar screw approx 8 turns press on the collar screw with your hand to push the wheel spindle out of the fork leg axle passage and remove the collar screw Hold the front wheel while you pull out the wheel spindle Lift the front wheel off the fork MAINTENANCE WORK ON CHASSIS AND ENGINE 49 Pr HP Take the left 4 and right distance bushing out of the shaft seal rings E CAUTION Do not operate the hand brake when the front wheel has been dismounted Be careful not to damage the brake disks when you lay the front wheel down Before you remount the front wheel clean and grease the shaft seal rings 5 and the bear ing surface A of the distance bushings and mount the distance bushings wide distance bushing in the left shaft seal ring When mounting the distance bushing be careful not to press the sealing lips towards the inside position the front wheel according to the running direction shown by the arrows B on the rim To mount lift the front wheel in the fork and mount the wheel spindle and collar screw 2 Tighten the collar screw to 60 Nm Position the brake calipers and bushings 6 and make sure the brake pads are correctly seated Apply Loctite 243 to the screws 1 mount the screws and tighten to 45 Nm Take the motorcycle off the front stan
74. r every 2 years ADD ON PARTS Replace the graphite gasket in the rear exhaust manifold slide Check actuating cables for damage smooth operation and kink less arrange ment adjust and lubricate Check the oil level in the hydraulic clutch reservoir Check air filter renew if necessary clean air filter box Check cables for damage and kink less arrangement Check headlamp adjustment Check electrical system for function low high beams stop light turn indica tors headlamp flasher tell tale lamps speedometer illumination horn side stand switch clutch switch emergency off switch Make sure all bolts and nuts are tight Check brake fluid level lining thickness and brake discs Change brake fluid Check brake lines for damage and leaks Check adjust smooth operation free travel of handbrake footbrake levers Check bolts of brake system for tight fit Check shock absorber and fork for leaks and proper operation Clean fork dust sleeves Bleed fork legs Check swinging fork pivot Check adjust steering head bearing Check all chassis bolts for tight fit fork plates fork leg axle nuts bolts swinging fork pivot reversing lever shock absorber PERIODIC MAINTENANCE SCHEDULE 34 990 SUPER DUKE R 2007 A clean motorcycle can be checked more quickly which saves money 1st Service after 1000 km every 7500 km or once a year
75. rate motorcycle specifications Different technical developments made it necessary to have a separate specification for four stroke motorcycles the JASO T903 MA standard Whereas TEMPERATUR car engines require long changing intervals motorcycle engines require a higher power out oc put at higher speeds Most motorcycle engines also use the same oil to lubricate the trans 32 F mission and the clutch The JASO MA standard responds to these special requirements Only use fully synthetic engine oils that meet the JASO MA quality requirements see infor 5W 40 10W 50 mation on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for temperatures over 0 C 32 F or 5W 40 for temperatures under 0 C 32 F Checking the engine oil level Check the engine oil level when the engine is warm at least 4 bars on the temperature indi cator light up Allow the warm engine to run idle for approx 1 minute and place the motor cycle on a level surface not on the side stand Wait 20 seconds to allow the oil level in the inspection glass to adjust to the oil level in the oil tank The oil level should be between the MIN and MAX marks add engine oil if necessary i CAUTION Always check the oil level when the engine is warm A cold engine can distort the measur ing results Engine oil expands when heated increasing the oil level MAINTENANCE WORK ON CHASSIS AND ENGINE 67 Ss Refilling engine oil
76. ront Malfuncti Stalls 41 Fuel pump relay Short circuit to ground positive Stalls 45 Lambda probe heater for rear cylinder Short circuit to ground positive Co ntinues to run 46 Lambda probe heater for front cylinder Short circuit to ground positive Co ntinues to run 49 Idle control motor Malfunction Co ntinues to run 53 Purge valve for carbon canister Short circuit to ground positive Co ntinues to run 54 Secondary air valve Short circuit to ground positive or interruption ntinues to run 65 EEPROM error Malfunction Co ntinues to run 68 Vacuum hose for front cylinder is defective Malfunction Co ntinues to run 69 Vacuum hose for rear cylinder is defective Malfunction Co ntinues to run 72 Stepper motor for 2nd throttle valve Malfunction Co ntinues to run CLEANING 71 Regular cleaning and paintwork care are part of the maintenance work and help to maintain the value of your motorcycle 1 CAUTION Never clean the motorcycle with a power washer or a strong water jet otherwise the pressure will allow water to enter the electric compo nents plugs cables bearings etc which can cause malfunctioning or can lead to premature wear of these components Before you wash your motorcycle close the muffler openings Use warm water with a commercial deterg
77. s the boiling point The brake fluid should therefore be changed at the prescribed intervals ZN WARNING OO Have the brake fluid for the front and rear brake changed at an authorized KTM workshop every 2 years BRAKE DISCS Wear reduces the thickness of the brake disc in the area of contact 4 with the brake pads The brake disk should not be thinner than 4 mm 0 16 in at the weakest point A Check the wear at several points ZN WARNING OOOO Brake disks that are less than 4 mm 0 16 in thick are a safety hazard Have worn brake disks replaced immediately MAINTENANCE WORK ON CHASSIS AND ENGINE 44 Adjusting the basic position of the hand brake lever The basic position of the hand brake lever can be modified by turning the adjusting screw 1 This lets you adapt the position of the pressure point the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disk to fit any hand i CAUTION At the hand brake lever free travel must at least be 3 mm 0 12 in Only then may the pis ton in the hand brake cylinder be moved to be recognized by the greater resistance of the hand brake lever If this free travel is not provided pressure will build up in the braking system and the front wheel brake may fail due to overheating Checking the front brake fluid level The brake fluid reservoir for the front brake is located on the left side of the handlebar and has a MI
78. tch is hydraulically actuated and adjusts itself automatically Hand brake lever The hand brake lever 2 is mounted on the handlebar on the right and actuates the front wheel brake The adjusting screw B is used to change the original position of the hand brake lever see maintenance work on chassis and engine OPERATION INSTRUMENTS 8 1810 LEnbth i Combined instrument The combined instrument is divided into 4 parts Function buttons to select the display modes and basic settings in the display Tachometer displays the engine speed Indicator lamps provide additional information on the motorcycle operating condition Display shows the speed cooling liquid temperature time ambient temperature distance traveled ODO trip master 1 TRIP 1 trip master 2 TRIP 2 distance traveled since the reserve warning lamp went on TRIP F Function buttons on combined instrument MODE 1 Briefly press the MODE button to go to the next display mode The available display modes are ambient temperature distance traveled ODO trip master 1 TRIP 1 and trip master 2 TRIP 2 The speed cooling liquid temperature and time are always displayed SET 2 Press the SET button to reset trip master 1 or 2 to O The 3rd button is not programmed Combined instrument display TEST When you switch on the ignition all of the display elements w
79. the reflector BULB FOR HIGH BEAM A Remove the rubber cap 2 and pull off the connector 3 Detach the retaining clip and remove the bulb Insert a new bulb attach the retaining clip connect the connector and mount the rubber cap BULB FOR LOW BEAM B Remove the rubber cap 4 and pull off the connector 5 Detach the retaining clip and remove the bulb When you insert the new bulb make sure the tab fits in the corresponding recess in the socket Attach the retaining clip connect the connector to the bulb and mount the rubber cap PARKING LIGHT BULB C Loosen the AH screw SW4 6 and push the right mask spoiler aside Pull out the bulb socket 7 and pull the light bulb out of the socket Mount the light bulb in the reverse order MAINTENANCE WORK ON CHASSIS AND ENGINE 58 USA design The parking light E is located in the upper part of the headlight in the USA design Bulb F see Technical specifications Chassis Lighting with high and low beams is mounted in the lower part of the headlight Connect the connectors to the connector support to check all of the bulbs for proper func tioning before you remount the headlight Adjusting the headlight range The payload can make it necessary to correct the headlight range The headlight range can be adjusted with the adjusting screw 1 Turning in a clockwise direction will increase the headlight range turning in a counterclockwise direction will reduc
80. the crash pads Unscrew the collar nut 1 remove the chain tensioner 2 hold the rear wheel while you pull out the wheel spindle 3 Push the rear wheel forward as far as possible and remove the chain from the rear sprocket Carefully take the rear wheel off the swing arm 1 CAUTION Do not operate the rear brake when the rear wheel has been dismounted Always place the wheel on the ground with the brake disc pointing upwards Otherwise the brake disc may be damaged If the axle is dismounted clean the thread of the wheel spindle and collar nut thoroughly and apply a new coat of grease Motorex Long Term 2000 to prevent the thread from jamming Before remounting the rear wheel clean and grease the bearing surface of the bushings 5 and the shaft seal ring 6 The rear wheel is remounted in the reverse order Make sure the chain tensioners 4 are mounted in the same way on the left and right The marks on the chain tensioners must be in the same position on the left and right in relation to the reference marks A Before you tighten the collar nut to 90 Nm press the rear wheel towards the front to allow the chain tensioner to rest against the clamping screws NOTE FOR SUPER DUKE R remount the crash pads MAINTENANCE WORK ON CHASSIS AND ENGINE 51 7 3 m AE If you don t happen to have a torque wrench at hand make sure you have the tighten ing torque corrected by a KTM dealer as soon as possible A loose wheel spind
81. the regulations effective in your country Never pour used oil in the sewer or dispose of it outdoors 1 liter of used oil will pollute 1 000 000 liters of water MAINTENANCE WORK ON CHASSIS AND ENGINE 37 O D S J Exi D Es Adjusting the fork and shock absorber There are a number of ways to adjust the fork and shock absorber to match the chassis to your driving style and the payload We have provided a table with pragmatical values to help you tune up your motorcycle These tune up specifications are reference values only and should serve as a basis for your per sonal chassis and suspension tuning Do not make arbitrary changes to the settings maxi mum 40 since this may impair the handling characteristics particularly in the high speed range Make sure both fork legs are equally adjusted A sticker with the basic settings is located under the seat BASIC SETTING FORK WP 4860 ROMA Maximum Payload Basic Setting Driving Sport aximum Payload Driving Comfort Race course Basic Setting Driving Sport Compression adjuster clicks r Rebound adjuster clicks Spring preload turns Adjusting compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed Turn the adjusting screws 1 clockwise to increase damping turn it counterclockwise to reduce damping during compression Make the same damping rate adjustme
82. ting on the motor cycle will increase the weight on the side stand The side stand or engine case can be damaged and the motorcycle can tip over DRIVING INSTRUCTIONS 30 Fuel In the condition at delivery the LC8 engine requires unleaded fuel with at least RON 95 USA Premium PON 91 see technical specifications engine After refueling it will take approx 3 minutes for the fuel warning lamp to switch off and for TRIP F to automatically reset to O and return to the previous display mode NOTE Press the SET key for 2 seconds to immediately turn off the fuel warning lamp i CAUTION This motorcycle is equipped with a catalytic converter that will be destroyed if you use leaded fuel Always use unleaded fuel Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig ZN WARNING OCS Gasoline is highly flammable and poisonous Extreme caution should be used when han dling gasoline Do not refuel the motorcycle near open flames or burning cigarettes Always switch off the engine before refuelling Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot Wipe up spills promptly If gasoline is swallowed or splashed in the eyes seek a doctor s advice immediately 31 PERIODIC MAINTENANCE SCHEDULE 32 1st Service every every 990 SUPER DUKE R 2007 after 7500 km 15000 km A clean motorcycle can be checked more quickly which saves mon
83. tion is provided in the chapter Adjusting the fork and shock absorber GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 22 Instructions for initial operation Make sure the work for the pre delivery inspection was performed by your author ized KTM workshop The DELIVERY CER TIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle Read these operating instructions care fully before your first ride Enter the chassis engine and key num bers on page 1 Familiarize yourself with the operating elements Adjust the clutch lever the hand brake lever the foot brake lever and the shift lever in the position that is most conven ient for you This motorcycle is equipped with a three way catalytic converter Leaded fuel will destroy the converter Always use unleaded fuel Get used to handling the motorcycle on an empty parking lot before starting on a longer drive Also try to drive as slowly as possible and in standing position to improve your feeling for the vehicle You may only be accompanied by a pas senger if your motorcycle is fitted and reg istered for such purposes The passenger must hold on to the supporting strap or the driver and keep his feet on the pas senger footrests throughout the ride Hold the handlebars with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when y
84. tures are expected to drop below 25 C 13 F Pressure induced by heating of the cooling liquid in the cooling system is controlled by a valve in the radiator cap 4 a water temperature rising up to 125 C 257 F is admissi ble without fear of problems Any excess cooling liquid caused by thermal expansion is conducted to the compensating tank 5 It will be sucked back in as soon as the temperature in the cooling system drops Checking the cooling liquid level in the compensating tank Check the level of the cooling liquid when the engine is cold It should fall between the MIN and MAX marks on the compensating tank 6 Add cooling liquid see above for mixture ratio if the cooling liquid level drops below the MIN mark If you need to add cooling liquid quite often the cooling system may leak If the compen sating tank is empty also check the cooling liquid level in the radiator Have the cooling system checked by an authorized KTM workshop MAINTENANCE WORK a CHASSIS AND ENGINE 62 Checking the cooling liquid level in the radiator Hold the radiator cap 1 with a cloth carefully turn in a counterclockwise direction and remove The radiator should be completely filled with cooling liquid no air should be in the radiator If any cooling liquid is missing the cooling system is probably leaking Have the cooling system checked at an authorized KTM workshop ZN WARNING
85. u ments will touch the fuel tank i CAUTION If the handlebar is tilted too far back the handlebar instruments may damage the fuel tank MAINTENANCE WORK ON CHASSIS AND ENGINE 65 How to change the handlebar position Super Duke R The upper triple clamp includes 2 bores arranged at a distance of 15 mm 0 6 in from one another Accordingly you can mount the handlebar in 2 different positions E CAUTION The steering angle is reduced if the handlebar is mounted in the rear position Adjust the steering lock so it does not hit the fuel tank Adjusting the steering damper Super Duke R The steering damper stabilizes the steering whenever the front wheel is relieved or off the ground The damping degree can be adjusted to harder or softer damping by turning the adjusting knob 1 BASIC SETTING Turn the adjusting knob all the way to the stop in a clockwise direction Turn 20 clicks in a counterclockwise direction Only change the setting by 3 clicks at a time and take a test ride MN WARNING Always check the steering for smooth operation before starting off on a ride Do not try to adjust the steering damper while driving Your attention will be distracted from the traffic and this may cause you to lose control of your motorcycle MAINTENANCE WORK ON CHASSIS AND ENGINE 66 Engine oil JASO T903 MA Automobile engine oil used to be used for four stroke motorcycles before there were sepa
86. ues to run 07 Sensor for 2nd throttle valve Output signal too low high Continues to run 09 Intake manifold air pressure for sensor rear cylinder Output signal too low high Continues to run 11 Intake manifold air pressure sensor for front cylinder Output signal too low high Continues to run TROUBLESHOOTING The blink code indicates which component is affected by an error This allows the error to be identified if no diagnosis tool is available BLINK CODE 16 SIGNAL COMPONENT ERROR DESCRIPTION ENGINE 12 Coolant temperature sensor Output signal too low high Co ntinues to run 13 Air temperature sensor Output signal too low high Co ntinues to run 14 Ambient air pressure sensor Output signal too low high Co ntinues to run 15 Tilt angle sensor Output signal too low high Co ntinues to run 17 Lambda probe for rear cylinder Malfuncti Co ntinues to run 18 Lambda probe for front cylinder Malfuncti Co ntinues to run 24 Control unit voltage supply Malfuncti Co ntinues to run 25 Side stand switch Short circuit to ground Co ntinues to run 33 Injection nozzle for rear cylinder Malfuncti Stalls 34 Injection nozzle for front cylinder Malfuncti Stalls 37 Ignition coil for rear cylinder Malfuncti Stalls 38 Injection coil for f
87. uid level 0 44 INDEX i Checking the front brake pads 0000000e 45 TROUBLESHOOTING on shed eita weston aa mais 72 Checking the rear brake fluid level 00 46t CLEANING Aia scott eee ake cee los or alte FLA anata a 8 77 Checking the rear brake pads 0000005 46 CONSERVATION FOR WINTER OPERATION 77 Dismounting and remounting the front wheel AS STORAGE 423 2 doth oi oe aaa Bee ah bak Bole Gull be wal hes 78 Dismounting and mounting the rear wheel 50 STARTING UP AFTER IMMOBILIZATION 78 TINGS alr PrOSSUPE sird anaa e E E R aw aes 51 TECHNICAL SPECIFICATIONS CHASSIS 79 Battery sonia ces 4 ara a a eb a r Renae R ike 52 TECHNICAL SPECIFICATIONS ENGINE 83 Removing and remounting the battery 53 EABINSON Aao hasa Lupa aa a Bobs a a baud ohed 84 Charging the battery 0 0 cece eee eee 54 HEAD WORD INDEX mari aa aaae eee eee 85 JUMP Staltavsc sated eee cadens ede ei kee Se dk a 54 CONSUMER INFORMATION FOR USA ONLY 87 Main TUSE erp t a aoe EA E E oa ae Caan as 55 Fuses for individual power consumers 0005 56 Replacing the headlight lamp nonna nananana 57 Adjusting the headlight range 0 000008 58 Replacing the brake light and taillight bulbs 59 Replacing the flasher bulbs 0 0000 cee eeae 59
88. uper Duke R Race course BASIC SETTING SHOCK ABSORBER WP 4618 BAVP Su per Duke n O D J xX D Bo Race course Compression adjuster clicks Maximum Payload 60 Basic Setting m P Compression adj Low Speed clicks Rebound adjuster clicks o gt N Compression adj High Speed turns ni Y Driving Comfort 5 Driving Sport Spring preload turns al S Driving Comfort a G amp G Basic Setting a S G Driving Sport a amp amp Driving Sport 16 o Maximum Payload 5 5 5 Rebound adjuster clicks N O 8 Spring 9 5 N mm 9 5 N mm Spring preload mm Oo a 00 amp Maximum Payload S in D Basic Setting 6 m p a O in o Maximum Payload a gt S S Basic Setting a Slil amp Driving Sport Air chamber length 110 mm 4 3 in Fork oil SAE 5 WP 4860 0401 Spring 170 185 180 185 TECHNICAL SPECIFICATIONS CHASSIS 81 TIGHTENING TORQUES CHASSIS 2007 Collar bolt on front wheel spindle M24x1 5 60 N Collar nut wheel spindle rear M25x1 5 90 N AH bolt shock absorber top bottom M14x1 5 80 N Collar nut for swing arm bolt M19x1 5 130 N AH bolts on subframe M8 Loctite 243 25 N AH bolts on back of footrest support M8 Loctite 243 25 N Engine carrier bolts 45N HH clamp bolts on top triple cl
89. urn the ignition key to position and firmly press it into the lock Turn the handlebar to the left then turn the ignition key to the left The ignition key can be withdrawn in position amp and A Combination switch The rocker switch LIGHTS 1 actuates the high beam or low beam D High beam light Z0 Low beam light The light signal high beam is actuated with button 2 as The indicator switch 3 returns to central position after actuation Press flasher switch towards switch housing to switch off the flasher pez The horn is sounded with button 4 OPERATION INSTRUMENTS 15 Starter tip switch Emergency OFF tip switch The emergency off switch 1 is provided for emergency situations and should not be used to switch off the engine The engine is ready for operation in position ignition circuit and starter circuit are switched on The engine cannot be started in position amp ignition circuit and starter circuit are inter rupted G Use the starter tip switch 3 to operate the electric starter Filler cap The filler cap 4 can be locked It is equipped with a tank ventilation system To open insert the ignition key turn 45 in a clockwise direction and tilt the filler cap back After refueling pull out the ignition key and press down on the filler cap until the lock engages OPERATION INSTRUMENTS 16 of Seat lock removing the seat The
90. y off switch for proper functioning 8 CHECK OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage 9 BAGGAGE PAYLOAD Never exceed the maximum total weight 387 kg 853 Ibs and the motorcycle s wheel loads The maximum total weight is comprised of the motorcycle in a running condition and refueled 199 kg 439 Ibs the baggage and accessories the driver and passenger with protective gear and helmet Adjust the tire inflation pressure as well as the preload and damping properties of the fork and shock absorber to the total weight Make sure your luggage is correctly fastened before you drive off 10 REAR MIRROR Sit on the motorcycle and check the adjustment of the rear mirror DRIVING INSTRUCTIONS Starting the engine 1 Switch on emergency OFF switch 1 2 Switch on ignition turn ignition key 2 into position NOTE You will hear the operation of the fuel pump for approx 2 seconds after switching on the ignition The FI indicator lamp will also light up during this time and the engine can not be started 3 Switch transmission to idle green indicator lamp N 3 lights up 4 Do not accelerate operate starter button 5 NOTE If you accelerate during the starting process you will hear a loud metallic sound caused by the torque limiter The torque limiter protects the components in the starter drive from being damaged 5 The oil pressure warnin

KTM 990 SUPER DUKE, 990 SUPER DUKE R Motorcycle User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents